Flexible roofing material



Feb. 27, 1951 T. H. KASHUBA FLEXIBLE ROOFING ummm.

2 Shasta-Sheet 1 Filed Jan. 27, 1947 mm a n w a m F 5% /fl 5 i 4 T.'H.KASHUBA FLEXIBLE ROOFING MATERIAL Feb. 27, 1951 2 Sheets-Sheet 2 FiledJan. 27. 1947 Patented Feb. 27, 1951 FLEXIBLE ROOFING MATERIAL TheodoreH. Kashuba, East Liverpool, .Ohio, assignor to T-K Roofing ManufacturingCompany, Chester, W. Va., a corporation of West Virginia ApplicationJanuary 27, 1947, Serial No. 724,679

4 Claims. (01. 1087) This invention relates to improvements in roofingmaterial and is more particularly concerned with a composition roofingmaterial of the type composed of a web of paper, felt, or other suitablefibrous material saturated and coated with asphalt and having one facethereof covered with suitable mineral granules, such as gravel, crushedstone, slate, etc. During the manufacture of composition roofingmaterial, the present invention contemplates the provision of anembossing operation in which the finished material is inserted through apair of embossing rolls which act to form longitudinally andtransversely disposed stripes on the granular coated surface of thematerial to simulate the appearance of shingles when the roofing stripsare laid in overlapping relation upon the roof of a building. The topedge portion of each strip of roofing material also has the granulespressed downwardly into and completely imbedded within the asphalticcoating material to provide a relatively smooth, tacky surface forlapping adhesive engagement with an overlaying strip, and it is anobject of the present invention to form a longitudinally extendingsealing ridge along said smooth tacky surface to coact with an overlyingshingle strip to prevent leakage due to water being blown upwardlybetween overlapping strips.

It is a further object of this invention to pro-- vide a roofing stripwhich is embossed to form abutment shoulders to facilitate alignment ofoverlying roofing strips, the abutment shoulders being formed andarranged to form part of the shingle pattern during the laying of aroof.

It is a further object of this invention to provide an embossed designin which the ends of adjacent shingle simulations are defined by closelyspaced parallel stripes which merge with spaced horizontally extendingstripes and thus present a more realistic shingle effect than hasheretofore been provided on roofing material.

It is a further object of this invention to provide a roofing materialadapted to be formed into rolls suitable for shipping or storage, and inwhich the embossed tacky surface of the strip will not become adhesivelyunited to adjacent convolutions within the roll.

It is a further object of this invention to provide an embossing rollwith circumferential and longitudinal ribs for embossing the granularcoated surface of the roofing strip, and to provide means for heatingthe embossing roll to cause the asphaltic material to fiow andcompletely cover the granules as the latter are pressed into the strimateri This invention embodies other novel features, details ofconstruction and arrangement of parts which are hereinafter set forth inthe specification and claims and illustrated in the accompanying drawingwherein:

Fig. 1 is a fragmentary plan view illustrating the method of applyingthe improved roofing strips to the roof of a building.

Fig. 2 is an enlarged transverse sectional view taken along the line 2-2of Fig. 1.

Fig. 3 is an enlarged fragmentary perspective view showing the sealingridge and alignment shoulders formed on the depressed lap portion of aroofing strip.

Fig. 4 is a plan view showing the roofing material prior to beingsevered longitudinally to form two similar roofing strips.

Fig. 5 is a perspective view showing a roll for embossing the surface ofthe roofing strip.

Referring now to the drawings for a better understanding of thisinvention, a flexible roofing strip is shown as comprising a web 8 offelt,

paper or other fibrous material saturated with asphalt or similarwaterproofing material. The outer or exposed surface of the web isprovided with a weather-protective layer 9 of high melting pointasphalt, or the like in which is partially imbedded a coating ll ofgranular material, such as crushed slate, gravel, or the like.

Roofing strips of the type thus described have heretofore been cut tolength and rolled up ready for market. As the entire exposed surface ofthis type of roofing material presents a rather monotonous uniform colorand appearance, the present invention contemplates the provision of animproved method and apparatus for providing the exposed granular coatedsurface H with an ornamental and artistic appearance.

After the granular coating H is applied to the strip or web 8, and whilethe protective layer 9 of asphalt is at a temperature of approximately275 to 300 F., the strip is inserted between a pair of rolls to embossthe exposed granular surface II to simulate the appearance of shingles.

Fig. 5 in the drawings illustrates an embossing roll l2 which coactswith a smooth surfaced roll (not shown) to form depressed horizontalstripes I3 and depressed vertical stripes II, the latter stripes beingarranged in pairs, to produce on the exposed surface of the strip 8 theeffect of shingles laid in overlapping rows, as illustrated in Fig. 1.The exposed granular coated surface ll of the strip is also depressedalong one edge thereof at IE to provide a lap edge for engagement underan overlying stri The depressed surface 16 forming the lap edge isformed with a longitudinally extending sealing ridge I! which is adaptedto engage against the underside of an overlying strip to prevent thepassage of water upwardly therebetween. Alignment projections l8 aredisposed along the depressed surface I8 to project toward the adjacentedge of the strip a distance substantially equal to the width of thehorizontal stripes l3 to facilitate alignment of overlyin strips and toalso carry out the appearance of equally spaced stripes l3 throughout aroof IS.

The roll l2 employed for embossing the granular coated surface ll ofroofing strip is formed with circumferential ribs 2| for formingdepressed horizontal stripes i3 and with closely spaced axial extendingribs 22 for forming the depressed vertical stripes l4-i4. One end of theroll i2 is formed with a raised circumferential portion 23 for formingthe depressed surface it along one edge of the roofing strip, and agroove 24 is formed in the raised surface 23 to form the longitudinallyextending sealing ridge I1. The inner edge of the raised portion 23 isnotched at spaced intervals at 26 to form the alignment projections 18at spaced intervals along the depressed surface l6 of the strip.

During the embossing operation, the granular coated strip is tightlycompressed between the embossing roll l2 and its coacting smoothsurfaced roll (not shown) to cause the raised surfaces on theembossing-roll to press the granular coating into the weather-protectivelayer 9 of high melting point asphalt. During the embossing operation,the embossing roll I2 is heated to a suitable temperature by means of agas flame to cause the asphalt to flow and completely cover the granularmaterial along the depressed portions of the strip, the depressedportions are thus caused to present a black, smooth, tacky surface freeof exposed granular material.

The strip is preferably formed from a sheet 3| approximately 36 or 37inches in width, shown in Fig. 4, which is cut longitudinally along itscenter at 32 to provide two similar finished strips approximately 18 or18% inches in width and of any suitable commercial length. The width ofl8-l8 inches is selected as this permits simulating the present mostpopular size of shingle. The stripes l3 and i4 define rectangularshinglelike formations 33 having a width of approximately 11 /2 inchesand a height of approximately five inches, the horizontal stripes beingapproximatelv of an inch wide, and the vertical stripes l4-i4 beingapproximately A; of an inch wide. The granular coated vertical strips34, defined by each pair of vertical stripes l4l4, are approximately ofan inch wide. The alignment shoulders I8 are formed of an inch in widthto corres ond with the width of the granular coated strip 34. Thedepressed lap surface H is approximately 2% to 2% inches in width, andthe sealing ridge I1 is disposed approximately one inch from the edge ofthe strip and extends upwardly from the lap surface It approximately ofan inch.

The strips are applied to the roof of a building in overlapping relationwith the lower edge of each strip above the first strip covering thedepressed lap surface iii of the adjacent lower strip. By forming anupstanding sealing ridge H extending along and projecting above theplane of the depressed surface It, a sharp line contacting engagement isprovided Within each lap joint to prevent the passage of water upwardlybetween 4 adjacent strips. It has also been found that the heat raysfrom the sun causes the lap portion .of adjacent strips to becomeadhesively'united,

and thus form a water-tight joint which is not readily broken by highvelocity wind storms. It will further be noted that the alignmentshoulders i 8 provided at spaced intervals along the depressed lapsurface I6 facilitate the alignment of adjacent strips during themounting of strips upon a roof.

Another important feature of this invention resides in the provision ofthe granular coated vertical strips 34 defined by each pair of verticalstripes l4,l4. After a roof has been covered by this type of roofingstrips, it presents the same appearance as a shingle covered roof andhas, therefore, been accorded a very favorable reception in the trade.

While this invention has been shown in but one form, it is obvious tothose skilled in the art that it is not so limited but is susceptible ofvarious changes and modifications without departing from the spirit andscope of the claimed invention.

I claim as my invention:

1. A building material comprising a strip of flexible waterproofmaterial having one side thereof coated with asphalt and mineralgranules, the coated side only of said strip being formed with depressedlongitudinal and transverse stripes defining raised shingle formations,the other side of said strip being fiat, said transverse stripes beingarranged in pairs to define narrow raised coated surfaces betweenadjacent shingle formations, one edge of said strip being compressed toprovide a, smooth depressed lap surface for adhesive engagement with thelower edge of an overlying strip, and alignment shoulders formed on theupper row of said shingle formations and arranged at mid-pointsthereabove to project onto said depressed lap surface a distancesubstantially equal to the width of said longitudinal stripes.

2. A building material comprising a strip of flexible waterproofmaterial having one side thereof coated with asphalt and mineralgranules, the coated side only of said strip being formed with depressedlongitudinal and transverse stripes defining raised shingle formations,the other side of said strip being fiat, said transverse stripes beingarranged in pairs to define narrow raised coated surfaces betweenadjacent shingle formations, one edge of said strip being compressed toprovide a smooth depressed lap surface for adhesive engagement with thelower edge of an overlying strip, a sealing ridge extending along andprojecting outwardly from said depressed lap surface for line engagementwith the underside of an overlying strip, and alignment shoulders formedon the upper row of said shingle formations and arranged at mid-pointsthereabove to project onto said depressed lap surface a distancesubstantially equal to the width of said longitudinal stripes.

3. A building material comprising a strip of flexible waterproofmaterial having one side thereof coated with asphalt and mineralgranules, the coated side only of said strip being formed with depressedlongitudinal and transverse stripes defining raised shingle formations,the other side of said strip being fiat, said transverse stripes beingarranged in pairs to define narrow raised coated surfaces betweenadjacent shingle formations, one edge of said strip being com-- pressedto provide'a smooth depressed lap surface for adhesive engagement withthe lower edge of an overlying strip, a sealing ridge extending alongand projecting outwardly from said depressed lap surface for lineengagement with the underside of an overlying strip, alignment shouldersformed on the upper row of saidshingle formations and arranged atmid-points thereabove to project onto said depressed lap surface adistance substantially equal to the width of said longitudinal stripes,said alignment shoulders having a width substantially equal to the widthof said narrow raised surfaces formed between adjacent shingleformations.

4. A building material comprising an elongated imperforate strip offlexible waterproof material having parallel edges one side thereofbeing coated with asphalt and mineral granules, the coated side only ofsaid strip being formed with depressed longitudinal and transversestripes defining raised shingle formations, the other side of said stripbeing flat, said transverse stripes being arranged in pairs to definenarrow raised coated surfaces between adjacent shingle formations, oneedge of said strip being embossed to provide a smooth depressed lapsurface for adhesive engagement with the lower edge of an REFERENCESCITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 2,115,172 Kirschbraun Apr. 26,1938 2,218,791 Herscovitz Oct. 22, 1940 2,260,334 Phillips Oct. 28, 19412,260,720 Morthland Oct. 28, 1941 2,289,298 Voigt July 7, 1942 2,382,234Koch Aug. 14, 1945

